EP2648320B1 - Moteur à courant continu sans balai et procédé de commande associé - Google Patents

Moteur à courant continu sans balai et procédé de commande associé Download PDF

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Publication number
EP2648320B1
EP2648320B1 EP11845675.5A EP11845675A EP2648320B1 EP 2648320 B1 EP2648320 B1 EP 2648320B1 EP 11845675 A EP11845675 A EP 11845675A EP 2648320 B1 EP2648320 B1 EP 2648320B1
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EP
European Patent Office
Prior art keywords
magnetic
rotor
brushless motor
stator
magnetic poles
Prior art date
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EP11845675.5A
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German (de)
English (en)
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EP2648320A1 (fr
EP2648320A4 (fr
Inventor
Akira Tsutsui
Kenichi Inoue
Kyoji Zaitsu
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Kobe Steel Ltd
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Kobe Steel Ltd
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Publication of EP2648320A4 publication Critical patent/EP2648320A4/fr
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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/08—Arrangements for controlling the speed or torque of a single motor
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/02—Details of the magnetic circuit characterised by the magnetic material
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/14—Stator cores with salient poles
    • H02K1/145—Stator cores with salient poles having an annular coil, e.g. of the claw-pole type
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K19/00—Synchronous motors or generators
    • H02K19/02—Synchronous motors
    • H02K19/10—Synchronous motors for multi-phase current
    • H02K19/103—Motors having windings on the stator and a variable reluctance soft-iron rotor without windings

Definitions

  • the present invention relates to a DC brushless motor and a method for controlling the DC brushless motor, and mainly relates to a motor that uses a powder magnetic core as an iron core and is driven by one-phase excitation.
  • a motor is used in wide fields as a part that converts electric power into motive power, such as automobiles, home-use electrical products, and industrial use.
  • a motor includes a stator that is a non-rotational part, and a rotor that rotates with an output shaft.
  • the stator and the rotor include an electromagnetic coil, a magnet, and an iron core.
  • PM motors are divided into several types in accordance with the principle for generating a driving force and the structure.
  • a motor of one type that uses one permanent magnet is called PM (permanent magnet) motor, and is particularly used in wide fields.
  • the PM motor includes the permanent magnet in a rotor.
  • a rotational force is generated by the interaction between an electromagnetic coil provided in a stator and a magnetic flux generated by the permanent magnet.
  • a motor serves as a power source, the motor is strongly desired to be reduced in size. To reduce the size, the motor has to generate a stronger magnetic force. To obtain the stronger magnetic force, a magnet that generates a strong magnetic flux is required.
  • a magnet that uses an Nd-Fe-B-based element has been developed (Nd: neodymium, Fe: iron, B: boron).
  • Nd neodymium, Fe: iron, B: boron
  • Dy disprosium
  • Nd a strong magnetic force
  • An effective method thereof may be increasing exciting current, or increasing turns of the electromagnetic coil.
  • the former method has a restriction by the sectional area of the coil, and the latter method has a restriction by the space in which the wire is wound.
  • the methods involve limitations.
  • the powder magnetic core is formed by forming an insulating film on the surface of soft magnetic powder, then compacting, and heat processing.
  • a motor hitherto uses a stack magnetic core in which electromagnetic steel sheets are punched and stacked. A magnetic flux hardly passes through the stack magnetic core in a stack direction, and easily passes through the stack magnetic core in a sheet plane direction. Hence, a magnetic circuit has been designed in plane.
  • the powder magnetic core since the above-described powder magnetic core is formed by compacting soft magnetic powder, the powder magnetic core may use a magnetic core material having an isotropic magnetic property and allowing a three-dimensional magnetic circuit to be designed.
  • the powder magnetic core may have a desirable shape by changing the shape of a die for compacting or by machining etc. after the compacting.
  • the three-dimensional magnetic design can provide a variety of motor core shapes. A flat motor or a small motor can be designed.
  • any of PTL 2 to PTL 4 discloses a claw teeth motor that uses a three-dimensional magnetic circuit. While a coil has been conventionally wound around each teeth, according to any of PTL 2 to PTL 4, a ring-shaped coil is arranged inside a claw pole iron core.
  • the disclosed claw teeth motor allows the size to be reduced by increasing the winding density, that is, by increasing the magnetic force. Also, by using the powder magnetic core, driving in an alternating magnetic field is available. If a stator has a three-layer structure with electrical angles being mutually shifted by 120°, the claw teeth motor disclosed in any of PTL 2 to PTL 4 also provides blushless driving in a three-phase alternating magnetic field.
  • any of PTL 2 to PTL 4 discloses the claw pole motor using the powder magnetic core.
  • the claw pole motor cannot rotate only by a one-phase basic structure. Hence, by stacking a plurality of pieces, a unit with three or more phases has to be formed.
  • magnetic circuits that contribute to generation of a torque on average correspond to two phases at maximum. Hence, a magnetic circuit for one phase is wasted in view of an output per volume.
  • a rotor requires a permanent magnet. Hence, the cost increases.
  • a demagnetization characteristic with temperature changes has to be considered. Hence, there are restrictions, for example, when a magnet is selected, the shape is designed, and a cooling system is designed.
  • US 3 950 663 A discloses a DC brushless motor, comprising: a stator including exciting coils; and a rotor provided coaxially to the stator, wherein the stator includes an iron core member having a plurality of protrusions, which serve as magnetic poles, the plurality of protrusions being formed in a circumferential direction at parallel sections wherein the rotor includes an iron core member having a plurality of protrusions, which serve as magnetic poles formed in the circumferential direction, wherein, from among the magnetic poles at the parallel sections, the corresponding top and bottom magnetic poles are positioned to be shifted in opposite directions in the circumferential direction with respect to a center line of the corresponding middle magnetic pole, and wherein a change in magnetic resistance between the stator and the rotor caused by a flow of a magnetic flux, which is generated around the exciting coils, is utilized as a driving force.
  • the present invention is made in light of the situations, and an object of the present invention is to provide a DC blushless motor and a method for controlling the DC brushless motor, the DC brushless motor which exhibits excellent space efficiency at low cost and is less affected by temperature changes.
  • a DC brushless motor according to the present invention is defined in claim 1.
  • the DC brushless motor configured as described above exhibits excellent space efficiency at low cost and is less affected by temperature changes.
  • a method of controlling a DC brushless motor according to the present invention is a method for controlling the above-described DC brushless motor that houses two exciting coils in two recesses of the E shape. The method includes applying plus current to one of the two exciting coils if the rotor is activated in a forward rotation direction; and applying minus current to the other exciting coil if the rotor is activated in a reverse rotation direction that is reverse to the forward rotation direction. Accordingly, the control method configured as described above can activate the DC brushless motor with the above-described configuration.
  • Fig. 1 is a sectional view in the axial direction of a DC brushless motor 1 according to a first embodiment.
  • Fig. 2 is a perspective view with part of the DC brushless motor 1 cut and removed.
  • Fig. 3 is a perspective view with part of a stator 2 cut and removed.
  • Figs. 4(A), 4(B), and 4(C) are sectional views perpendicular to the axis, in sectional planes A-A, B-B, and C-C in Fig. 1 of the DC brushless motor.
  • Fig. 5 is an exploded perspective view of the stator 2.
  • the DC brushless motor 1 mainly includes the stator 2 having two exciting coils 31 and 32, and a rotor 4 that is an inner rotor coaxially provided in the stator 2.
  • the DC brushless motor 1 is a motor that performs SR operation in which a change in magnetic resistance between the stator 2 and the rotor 4 caused by a flow of a magnetic flux generated around the exciting coils 31 and 32 is utilized as a driving force.
  • the exciting coils 31 and 32 have a two-layer structure, and have the following configuration.
  • an iron core member 20 of the stator 2 includes members 21, 22, and 23 that are divided into three in the axis Z direction.
  • the iron core member 20 has a substantially E-shaped cross-section in the axis Z direction at a radius part.
  • a plurality of protrusions 212, 222, and 232 serving as magnetic poles are formed on three parallel sections 211, 221, and 231 of the E shape periodically in the circumferential direction as shown in Fig. 4 . That is, in the case of such an inner rotor, the iron core member 20 of the stator 2 at the outer periphery side has a shape in which three edges (rings) extend from a cylindrical outer wall toward the inner periphery side.
  • the numbers of the protrusions (magnetic poles) 212, 222, and 232 are the same. Also, as shown in Fig. 4 , the corresponding top and bottom magnetic poles 212 and 232 are positioned to be shifted in the opposite directions by equal angles ⁇ with respect to the center line of the corresponding middle magnetic pole 222.
  • the ring-shaped exciting coils 31 and 32 are respectively housed in two recesses 24 and 25 of the E shape.
  • the top and bottom members 21 and 23 each have a substantially L-shaped section in the axis Z direction when the member is developed in the circumferential direction.
  • L-shaped peripheral walls 213 and 233 are closed with the middle member 22, and hence the recesses 24 and 25 are formed.
  • the stator 2 is assembled.
  • the exciting coils 31 and 32 are each formed by winding a strip-shaped conductive member such that the width direction of the strip-shaped conductive member extends along the rotation-axis Z direction of the exciting coils 31 and 32.
  • Fig. 6 illustrates a result of magnetic field analysis showing a flow of a magnetic flux when electricity is applied to the exciting coils 31 and 32 of the DC brushless motor 1.
  • Fig. 6(A) shows a result of the magnetic field analysis if the thickness of the protrusion (magnetic pole) 222 of the middle member 22 is 0.6 times the thickness
  • Fig. 6(B) shows a result of the magnetic field analysis if the thickness is 1.5 times the thickness
  • Fig. 6(C) shows a result of the magnetic field analysis if the thickness is 1.9 times the thickness 1.
  • the thickness of the protrusions (magnetic poles) 222 of the middle member 22 is decreased, the magnetic flux that leaks to the surface of the rotor 4 from positions other than distal ends of the protrusions (magnetic poles) 212, 222, and 232 are increased.
  • the thickness of the protrusions (magnetic poles) 222 of the middle member 22 is preferably at least 1.5 times the thickness of the protrusions (magnetic poles) 212 and 232 of the top and bottom members 21 and 23.
  • the rotor 4 is formed of an iron core member 40 having a plurality of protrusions 41, which serve as magnetic poles and are formed periodically in the circumferential direction.
  • An output shaft 42 of the rotor 4 may be a separate member that is press fitted to the iron core member 40, or may be integrally molded with the iron core member 40.
  • Fig. 8 illustrates an example of a driving circuit 5 of the DC brushless motor 1 configured as described above.
  • the exciting coils 31 and 32 with the above-described two-layer structure have to generate magnetic fields in the opposite directions as shown in Fig. 1 .
  • the exciting coils 31 and 32 are connected in series when during acceleration and normal rotation, and driven with a rectangular-wave pulse (described later).
  • the exciting coils 31 and 32 are formed to be equivalent as shown in Fig. 5 (in Fig. 5 , both the coils are wound clockwise when viewed from above), the directions of current have to be opposite to each other.
  • an inner peripheral end (311) of one exciting coil (31) is connected with an outer peripheral end (321) of the other exciting coil (32), and an outer peripheral end (312) of the one exciting coil (31) and an inner peripheral end (322) of the other exciting coil (32) are respectively connected with lines 52 and 53 extending from a direct-current power supply 51 in the driving circuit 5.
  • a switch element Tr0 that controls application of electricity is arranged in one of the lines 52 and 53 (in Fig. 8 , 52 at the high side).
  • selection switch elements Tr1 and Tr2 for forward and reverse rotation directions are arranged in series between the lines 52 and 53.
  • the inner peripheral end (311) of the one exciting coil (31) and the outer peripheral end (321) of the other exciting coil (32) are connected with a node 54 between the selection switch elements Tr1 and Tr2.
  • the inner peripheral ends (311, 322) may be connected with one of the lines 52, 53 and the node 54 and the outer peripheral ends (312, 321) may be connected with the other of the lines 52, 53 and the node 54.
  • Fig. 9 is a waveform diagram for explaining a driving method by the driving circuit 5 configured as described above.
  • Fig. 9(A) shows a case of forward rotation driving
  • Fig. 9(B) shows a case of reverse rotation driving.
  • Fig. 9 shows a driving waveform when it is assumed that the exciting coils 31 and 32 are equivalent.
  • the inductance characteristic of the DC brushless motor 1 in Fig. 4 is, for example, as shown in Fig. 10.
  • FIG. 10 illustrates a calculation result of an inductance L( ⁇ ) with rotation for a half cycle, when the number of the magnetic poles of the rotor 4 and the stator 2 is four, a magnetic pole width ⁇ of each of the magnetic poles of the rotor 4 with respect to a period of the magnetic pole is 40%, in the stator 2, a magnetic pole width ⁇ in the circumferential direction of each of the protrusions (magnetic poles) 212 and 232 at the top and bottom is 40% and a magnetic pole width ⁇ in the circumferential direction of each of the protrusions (magnetic poles) 222 at the middle is 50%, and a shift angle ⁇ of the corresponding protrusions (magnetic poles) 212 and 232 at the top and bottom with respect to the corresponding magnetic pole 222 at the middle is 18°.
  • a calculation result #1 indicated by a solid line represents an inductance of the one exciting coil 31
  • a calculation result #2 indicated by a broken line represents an inductance of the other exciting coil 32
  • a result #1+#2 indicated by a dotted-chain line represents a combined inductance of both the exciting coils 31 and 32.
  • the exciting coils 31 and 32 are driven by current with opposite phases, and hence driven with quasi-two phases. If the winding directions of the exciting coils 31 and 32 are opposite to each other, the exciting coils 31 and 32 are driven by current with the same phase. However, as described below, the exciting coils 31 and 32 are individually controlled by switching according to the activation.
  • the selection switch element Tr1 is kept OFF, the selection switch element Tr2 and the switch element Tr0 are turned ON, hence a current path from the direct-current power supply 51 to the switch element Tr0, the exciting coil 31, the selection switch element Tr2, and then the direct-current power supply 51 is formed and activated. Then, the selection switch Tr2 is turned OFF, and hence the current path is switched to a current path from the direct-current power supply 51 to the switch element Tr0, the exciting coil 31, the exciting coil 32, and then the direct-current power supply 51. By turning ON/OFF the switch element Tr0, rectangular-wave current is applied.
  • the selection switch element Tr2 is kept OFF, the selection switch element Tr1 and the switch element Tr0 are turned ON, hence a current path from the direct-current power supply 51 to the switch element Tr0, the selection switch element Tr1, the exciting coil 32, and then the direct-current power supply 51 is formed and activated. Then, the selection switch Tr1 is turned OFF, and hence the current path is switched to a current path from the direct-current power supply 51 to the switch element Tr0 the exciting coil 31, the exciting coil 32, and then the direct-current power supply 51. By turning ON/OFF the switch element Tr0, rectangular-wave current is applied.
  • a current pulse to the exciting coil at the follow side (the side to which current is applied later) is preferably applied with delay.
  • a time difference ⁇ is provided between first current pulses that are applied to both the exciting coils.
  • Fig. 11(A) and Fig. 11(B) respectively correspond to Fig. 9(A) and Fig. 9(B) .
  • the time difference ⁇ is decreased as the rotation speed increases, and the time difference ⁇ is increased as a shift ⁇ between the protrusions (magnetic poles) 212 and 232 increases.
  • Such control is made by a control circuit (not shown) in response to a detection result of a rotation angle position of the rotor 4 by an encoder (not shown). With this configuration, the DC brushless motor 1 can be further efficiently accelerated.
  • the activation current is not limited to a single pulse as shown in Figs. 9 and 11 , and may be a plurality of pulses. If an element that can output current with a variable voltage is used, the activation current may be a triangular wave. Even if the same activation pulse or drive pulse is input, the actual response to the pulse varies in accordance with the position of activation or the weight of a load. Hence, Figs. 9 and 11 show merely examples.
  • the control circuit successively controls the number of activation pulses or the peak value of the drive pulse in response to the detection result of the encoder.
  • an approximation model is used, in which a gap (g) between the magnetic poles of the stator 2 and the rotor 4 is sufficiently small and the magnetic flux lines pass through only a region where the magnetic poles overlap each other.
  • an inductance of an equivalent magnetic circuit of this motor structure is inversely proportional to a series magnetic resistance of a magnetic resistance between the protrusions (magnetic poles) 212, 232 and the rotor 4 and a magnetic resistance between the rotor 4 and the protrusions (magnetic poles) 222.
  • gupper is a gap length between the protrusions (magnetic poles) 212, 232 and the protrusions (magnetic poles) 41 of the rotor 4
  • glower is a gap length between the protrusions (magnetic poles) 222 and the protrusions (magnetic poles) 41 of the rotor 4
  • S upper ( ⁇ ) is an overlap area between facing surfaces of the protrusions (magnetic poles) 212, 232 and the protrusions (magnetic poles) 41 of the rotor 4
  • S lower ( ⁇ ) is an overlap area between facing surfaces of the protrusions (magnetic poles) 222 and the protrusions (magnetic poles) 41 of the rotor 4.
  • the overlap area of the magnetic poles is the inductance L
  • the magnitude of the torque can be approximately evaluated by a difference ⁇ L between a maximum value Lmax and a minimum value Lmin of the inductance L.
  • Figs. 12 to 14 like the aforementioned case in Fig. 10 , the number of magnetic poles of the rotor 4 and the stator 2 is four. However, In Figs. 12 to 14 , the shift angle ⁇ between the protrusions (magnetic poles) 212 and 232 at the top and bottom is 22.5°. In Figs. 10 , 13 , and 14 , the magnetic pole width ⁇ in the circumferential direction of the protrusions (magnetic poles) 222 at the middle is 50%, and in Fig. 12 , the magnetic pole width ⁇ is 40%.
  • the magnetic pole width ⁇ in the circumferential direction of the protrusions (magnetic poles) 212 and 232 at the top and bottom is 50% in Figs. 13 and 14 , is 40% in Fig. 10 , and is 30% in Fig. 12 .
  • the magnetic pole width ⁇ in the circumferential direction of the protrusions (magnetic poles) 41 of the rotor 4 is 50% in Figs. 12 and 13 , is 40% in Fig. 10 , and is 55% in Fig. 14 .
  • the magnetic pole width ⁇ meets 30% ⁇ .
  • the magnetic pole width meets ⁇ ⁇ ⁇ , ⁇ to capture many magnetic fluxes of the protrusions (magnetic poles) 212 and 232 at the top and bottom.
  • the minimum value Lmin of the inductance L( ⁇ ) is 0.
  • the minimum value Lmin is not 0 in Fig. 14 .
  • the magnetic pole widths ⁇ and ⁇ meet ⁇ , ⁇ ⁇ 55%. With the relationships, the magnetic pole widths ⁇ , ⁇ , and ⁇ meet 30% ⁇ ⁇ ⁇ ⁇ , ⁇ ⁇ 55%.
  • the activation gradient is obtained in an area around the maximum value Lmax; however, the activation torque is not obtained in an area near the minimum value Lmin.
  • the inductance during SR driving has two types of balanced points for the maximum value Lmax and minimum value Lmin.
  • Each balanced point corresponds to a "stable point” at which the magnetic poles face each other, or an "unstable point” at which the magnetic poles are alternately arranged. Unless an abnormal external force acts, the rotor does not stay at the latter point at rest. Hence, the activation can be made even under the condition that the magnetic pole width ⁇ of the rotor 4 is 50%.
  • a ratio ⁇ of a circumferential length of a distal end of each of the protrusions (magnetic poles) 41 of the rotor 4, in a cylindrical plane of a locus of the distal end of the protrusion (magnetic pole) 41 of the rotor 4, preferably meets 30% ⁇ ⁇ ⁇ 55% (i.e., a ratio of a gap between the protrusions (magnetic poles) 41 is preferably 70% or lower and 45% or higher).
  • Table 1 shows a result of comparison between the DC brushless motor 1 according to this embodiment and a motor of each type according to related art.
  • This embodiment ⁇ Not expensive (plenty) Core/wire structure Complicated ⁇ ⁇ Simple
  • the DC brushless motor 1 performs operation of a SR motor that does not require a permanent magnet and can be realized with an inexpensive material, and can be decreased in cost by simplifying the core and wire structure like the claw teeth motor or the claw pole motor. Also, the DC brushless motor 1 according to this embodiment does not have to consider thermal demagnetization of a magnet, and hence can be operated at high temperatures as compared with a PM motor.
  • this SR motor does not generate a rotational magnetic field with one phase, a torque cannot be obtained at rest depending on the rotation angle. Hence, independent activation may not be made.
  • a SR motor switched reluctance motor
  • a SR motor is rotated by a change in magnetic resistance as a driving force. Hence, at a rotation angle position without a change in magnetic resistance, a torque cannot be obtained.
  • the motor can be rotated by the inertia even at a rotation angle without a torque.
  • the motor cannot be activated at rest at a rotation angle without a torque.
  • the exciting coils 31 and 32 have the two-layer structure
  • the iron core member 20 of the stator 2 has the substantially E-shaped cross-section in the axis Z direction when the iron core member 20 is developed in the circumferential direction
  • the plurality of protrusions 212, 222, and 232 serving as the magnetic poles are formed periodically in the circumferential direction at the three parallel sections 211, 221, and 231 of the E shape
  • the ring-shaped exciting coils 31 and 32 are respectively housed in the two recesses 24 and 25 of the E shape.
  • the rotor 4 is formed of the iron core member 40 having the plurality of protrusions 41 serving as the magnetic poles periodically in the circumferential direction.
  • the numbers of the protrusions (magnetic poles) 212, 222, and 232 at the three parallel sections 211, 221, and 231 of the E shape are equivalent.
  • the corresponding protrusions (magnetic poles) 212 and 232 at the top and bottom are positioned to be shifted in the opposite directions with respect to the center line of the corresponding protrusion (magnetic pole) 222 at the middle.
  • the SR motor which is not rotated by one phase can be activated, and when the rotation is started, magnetic circuits for two phases constantly contribute to generation of a torque.
  • space efficiency output per size
  • the SR motor can obtain a torque required for rotation of the rotor without a magnet by utilizing a change in magnetic resistance between the rotor and the stator as a driving force. Accordingly, with the DC brushless motor that is a power source necessary for industrial use and consumer use, rare metal in rare earth magnet etc. can be saved.
  • the DC brushless motor 1 when the corresponding protrusions (magnetic poles) 212 and 232 at the top and bottom are shifted in the opposite directions with respect to the center line Y of the corresponding protrusion (magnetic pole) 222 at the middle, by arranging the protrusions at the same distance (angle ⁇ ), in other words, by equalizing the shift, the torque can become almost uniform.
  • the exciting coils 31 and 32 are each formed by winding the strip-shaped conductive member in a flatwise manner so that the width direction thereof extends along the rotation-axis Z direction of the exciting coils 31 and 32.
  • the coil is formed of a conductor, eddy current is generated in a plane perpendicular to magnetic force lines (orthogonal plane) shown in Figs. 1 and 6 , and a loss is generated by the eddy current.
  • the magnitude of the eddy current is proportional to the area of a plane intersecting with the magnetic flux lines, i.e., the area of a continuous plane perpendicular to the magnetic flux lines if the magnetic flux density is the same. Since the magnetic flux lines extend along the axial direction in the coil, the eddy current is proportional to the area of a plane in a radial direction orthogonal to the axis Z direction of the conductor that forms the coil.
  • the strip-shaped conductive member that forms the exciting coils 31 and 32 is preferably formed such that a ratio t/W of a thickness t in the radial direction to a width W is 1/10 or smaller.
  • the strip-shaped conductive member can be wound without a gap, the current density can be increased and heat can be efficiently radiated from the inside of the conductive member, as compared with a case in which a cylindrical elemental wire is wound.
  • the thickness t of the conductive member is equal to or smaller than a skin thickness with respect to a frequency of alternating current power fed to the exciting coils 31 and 32, the eddy current loss can be further decreased.
  • the gap that is generated between the exciting coils 31, 32, and the recesses 24, 25 of the stator 2 is preferably filled with a thermally conductive member.
  • inner surfaces of the sections 211 and 231 of the stator 2 facing one ends of the exciting coils 31 and 32 in the rotation-axis Z direction, and an inner surface of the section 221 facing the other ends are preferably formed in parallel at least in a region covering the ends.
  • the exciting coils 31 and 32 are set for the exciting coils 31 and 32 (the wire structure is the flatwise wire structure and the width W is larger than the thickness t), if the sections 211, 221, and 231 that cover both upper and lower end surfaces of the exciting coils 31 and 32 have an inclination, the magnetic flux lines (magnetic force lines) that actually pass through the inside of the exciting coils 31 and 32 are not substantially parallel to the rotation-axis Z direction particularly in areas near both the upper and lower end surfaces.
  • the inventor of this case verified the distribution of magnetic flux lines while the degree of parallelism of the inner wall surfaces of the sections 211, 221, and 231 was changed. For example, if the degree of parallelism is 1/100, the magnetic flux lines passing through the inside of the exciting coils 31 and 32 are parallel to the rotation-axis Z direction. If the degree of parallelism is -1/10 or 1/10, the magnetic flux lines passing through the inside of the exciting coils 31 and 32 are not parallel to the rotation-axis Z direction. With this verification, to allow the magnetic flux lines passing through the inside of the exciting coils 31 and 32 to be parallel, the absolute value of the degree of parallelism is preferably 1/50 or smaller.
  • the iron core members of the stator 2 and the rotor 4 are each preferably formed of any of a powder magnetic core made of iron-base soft magnetic powder, a ferrite magnetic core, and a magnetic core made of a soft magnetic material in which soft magnetic alloy powder is dispersed in resin.
  • the two magnetic cores of the rotor 4 and the stator 2 can be molded into optimally complicated desirable shapes. A desirable magnetic property can be relatively easily obtained, and the magnetic cores can be relatively easily formed into desirable shapes.
  • the soft magnetic powder is ferromagnetic metal powder. More specifically, the soft magnetic powder may be, for example, pure iron powder, iron-base alloy powder (Fe-A1 alloy, Fe-Si alloy, Sendust, a permalloy, etc.), amorphous powder, and iron powder with an electrical insulating film, such as a phosphoric acid chemical conversion film, being formed on the surface thereof.
  • the soft magnetic material may be manufactured by, for example, a method of microparticulation by atomizing etc., or a method of pulverizing iron oxide etc. and then reconstituting the pulverized iron oxide.
  • Such soft magnetic powder may be used solely or by mixing with non-magnetic powder such as resin.
  • the ratio of the mixture can be relatively easily adjusted. By properly adjusting the mixture ratio, the magnetic property of the magnetic core member can easily attain a desirable magnetic property.
  • the material of the two exciting coils 31 and 32 that form the stator 2 , and the material of the rotor 4 are preferably the same material in view of cost reduction.
  • Fig. 16 is a perspective view showing an inner structure when a casing of a DC brushless motor 1a according to a second embodiment is removed.
  • Fig. 17 is an exploded perspective view of the DC brushless motor 1a.
  • Fig. 17(A) is an exploded perspective view of a stator 2a.
  • Fig. 17(B) is an exploded perspective view of a rotor 4a. While the DC brushless motor according to the first embodiment is an inner rotor, the DC brushless motor 1a according to the second embodiment is an outer rotor.
  • the stator 2a at the inner periphery side is fixed to a fixed shaft 43, and the rotor 4a is provided at the outer periphery side of the stator 2a.
  • the same reference sign and an alphabetic character a are applied to the part having a function corresponding to that of the DC brushless motor 1. Accordingly, functions of parts are easily understood.
  • an iron core member 20a of the stator 2a has a substantially E-shaped cross-section in the axis Z direction when being developed in the circumferential direction, a plurality of protrusions 212a, 222a, and 232a serving as magnetic poles are formed at three parallel sections 211a, 221a, and 231a of the E shape periodically in the circumferential direction, and the ring-shaped exciting coils 31 and 32 are respectively housed in two recesses of the E shape.
  • the numbers of protrusions (magnetic poles) 212a, 222a, and 232a at the three parallel sections 211a, 221a, and 231a of the E shape are equivalent.
  • the corresponding protrusions (magnetic poles) 212a and 232a at the top and bottom are positioned to be evenly shifted in the opposite directions with respect to the center line of the corresponding protrusion (magnetic pole) 222a at the middle.
  • the rotor 4a is formed of an iron core member 40a having a plurality of protrusions 41a serving as magnetic poles periodically in the circumferential direction. With this configuration, the outer rotor structure can be also realized.
  • Fig. 18 is a sectional view perpendicular to the axis of a DC brushless motor 1b according to a third embodiment.
  • the protrusions (magnetic poles) 212, 222, and 232 of the stator 2 and the protrusions (magnetic poles) 41 of the rotor 4 each have an arcuate section in a plane perpendicular to the axis.
  • protrusions (magnetic poles) 212b, 222b, and 232b of a stator 2b and protrusions (magnetic poles) 41b of a rotor 4b are each formed in a rectangular shape like a stepping motor.
  • Fig. 19 is a sectional view perpendicular to the axis of a DC brushless motor 1c according to a fourth embodiment.
  • the protrusions (magnetic poles) 212, 222, and 232 of the stator 2 and the protrusions (magnetic poles) 41 of the rotor 4 have four pole configurations.
  • protrusions (magnetic poles) 212c, 222c, and 232c of a stator 2c and protrusions (magnetic poles) 41c of a rotor 4c have five pole configurations.
  • Figs. 19(A), 19(B), and 19(C) respectively correspond to Figs. 4(A), 4(B), and 4(C) showing the sectional views at the positions cut along A-A, B-B, and C-C in Fig. 1 .
  • the number of magnetic poles and the shapes of the magnetic poles may be desirably selected.
  • a DC brushless motor includes a stator including exciting coils; and a rotor provided coaxially to the stator.
  • a change in magnetic resistance between the stator and the rotor caused by a flow of a magnetic flux, which is generated around the exciting coils, is utilized as a driving force.
  • the stator includes an iron core member having a substantially E-shaped cross-section in an axial direction at a radius part and having a plurality of protrusions, which serve as magnetic poles and are formed in a circumferential direction at each of three parallel sections of the E shape, and the ring-shaped exciting coils housed in two recesses of the E shape.
  • the rotor includes an iron core member having a plurality of protrusions, which serve as magnetic poles and are formed in the circumferential direction.
  • the numbers of the magnetic poles at the three parallel sections of the E shape are equivalent. From among the magnetic poles at the three parallel sections of the E shape, the corresponding top and bottom magnetic poles are positioned to be shifted in opposite directions in the circumferential direction with respect to a center line of the corresponding middle magnetic pole.
  • a SR motor has been used for a motor not using a permanent magnet.
  • This SR motor is a motor that uses a reluctance torque caused by a change in magnetic resistance with rotation, and that is rotated by successively switching application of current to a coil of a stator to which a protruding pole of a rotor approaches.
  • the cost is low, and thermal demagnetization of a magnet does not have to be considered. Accordingly, operation at high temperatures can be performed as compared with the aforementioned PM motor.
  • this SR motor does not generate a rotational magnetic field with one phase, a torque cannot be obtained at rest depending on the rotation angle. Hence, independent activation may not be made.
  • the SR motor is rotated by a change in magnetic resistance as a driving force. Hence, at a rotation angle position without a change in magnetic resistance, a torque cannot be obtained.
  • the motor can be rotated by the inertia even at a rotation angle without a torque.
  • the motor cannot be activated at rest at a rotation angle without a torque. Thus, the motor cannot be rotated.
  • an iron core member having a substantially E-shaped cross-section in the axial direction at a radius part and having a plurality of protrusions, which serve as magnetic poles and are formed in the circumferential direction at each of three parallel sections of the E shape, and the ring-shaped exciting coils housed in two recesses of the E shape.
  • the iron core member of the stator at the outer periphery side has a shape in which three edges (rings) extend from a cylindrical outer wall toward the inner periphery side.
  • the rotor includes an iron core member having a plurality of protrusions, which serve as magnetic poles and are formed in the circumferential direction.
  • the numbers of the magnetic poles at the three parallel sections of the E shape are equivalent. From among the magnetic poles at the three parallel sections of the E shape, the corresponding top and bottom magnetic poles are positioned to be shifted in the opposite directions in the circumferential direction with respect to the center line of the corresponding middle magnetic pole.
  • a method for controlling the DC brushless motor configured as described above includes applying plus current to one of the two exciting coils if the rotor is activated in a forward rotation direction; and applying minus current to the other exciting coil if the rotor is activated in a reverse rotation direction that is reverse to the forward rotation direction. Then, when the rotor is activated to be rotated, rectangular-wave current is preferably applied. Accordingly, acceleration or normal rotation can be provided.
  • the SR motor which is not rotated by one phase can be activated, and when the rotation is started, the magnetic circuits for the two phases constantly contribute to the generation of a torque.
  • space efficiency output per size
  • the corresponding top and bottom magnetic poles are positioned to be shifted in the opposite directions in the circumferential direction by the same distance (angle) with respect to the center line of the corresponding middle magnetic pole.
  • the rotor is housed at an inner periphery side of the stator, and a ratio ⁇ of a circumferential length of a distal end of each of the protrusions of the rotor, in a cylindrical plane of a locus of the distal end of the protrusion of the rotor, (a ratio of a width in the circumferential direction of a distal end of each magnetic pole to a period of the magnetic pole; a ratio of total widths in the circumferential direction of the magnetic poles of the rotor to the entire circumference) meets 30% ⁇ ⁇ ⁇ 55%.
  • the ratio ⁇ of the circumferential length of the distal end of each protrusion, in a cylindrical plane of a locus of the distal end of the protrusion of the rotor is equal to or higher than 30% and equal to or lower than 55% (i.e., the gap between the protrusions is 70% or lower and 45% or higher). Accordingly, the DC brushless motor configured as described above can generate a large torque.
  • the exciting coils are each formed by winding a strip-shaped conductive member so that a width direction of the conductive member extends along a rotation axis direction of the exciting coil.
  • the DC brushless motor configured as described above, by forming the exciting coils as described above, eddy current that is generated at the exciting coils can be restricted, and heat generation can be restricted. Also, since the strip-shaped conductor member can be wound without a gap, with the DC brushless motor configured as described above, the current density can be increased and heat can be efficiently radiated from the inside of the conductor member, as compared with a case in which a cylindrical elemental wire is wound.
  • the iron core members of the stator and the rotor are each formed of any of a powder magnetic core made of iron-base soft magnetic powder, a ferrite magnetic core, and a magnetic core made of a soft magnetic material in which soft magnetic alloy powder is dispersed in resin.
  • the stator and the rotor can be molded into optimal complicated desirable shapes.
  • the DC brushless motor and the method for controlling the DC brushless motor can be provided.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
  • Control Of Motors That Do Not Use Commutators (AREA)
  • Synchronous Machinery (AREA)

Claims (6)

  1. Moteur à courant continu sans balai (1), comprenant :
    un stator (2) comprenant des bobines excitantes (31 ; 32) ; et
    un rotor (4) disposé coaxialement au stator (2),
    dans lequel le stator (2) comprend
    un élément à noyau de fer (20) présentant une coupe transversale essentiellement en forme de E dans un sens axial à une partie de rayon et présentant une pluralité de saillies (212, 222, 232) qui servent de pôles magnétiques et sont formées dans une direction circonférentielle à chacune de trois sections parallèles (211, 221, 231) de la forme en E, et les bobines excitants annulaires (31 ; 32) étant logées dans deux évidements de la forme en E,
    dans lequel le rotor (4) comprend un élément à noyau de fer (40) présentant une pluralité de saillies (41) qui servent de pôles magnétiques formés dans la direction circonférentielle,
    dans lequel les nombres de pôles magnétiques aux trois sections parallèles (211, 221, 231) de la forme en E sont équivalents,
    dans lequel, parmi les pôles magnétiques aux trois sections parallèles (211, 221, 231) de la forme en E, les pôles magnétiques supérieurs et inférieurs correspondants sont positionnés de manière à être déplacés en sens opposés dans la direction circonférentielle par rapport à une ligne médiane du pôle magnétique central correspondant,
    dans lequel une modification de la résistance magnétique entre le stator (2) et le rotor (4) causée par l'écoulement d'un magnétique flux généré autour des bobines excitantes (31 ; 32) est utilisée comme force motrice,
    et dans lequel les pôles magnétiques supérieurs et inférieurs correspondants sont positionnés de manière à être déplacés dans les sens opposés dans la direction circonférentielle de la même distance par rapport à la ligne médiane du pôle magnétique central correspondant.
  2. Moteur à courant continu sans balai (1) selon la revendication 1,
    dans lequel le rotor (4) est logé à une face périphérique intérieure du stator (2), et dans lequel un rapport α d'une longueur circonférentielle d'une extrémité distale de chacune des saillies (41) du rotor (4), dans un plan cylindrique d'un locus de l'extrémité distale des saillies (41), est conforme à 30% ≤α≤ 55%.
  3. Moteur à courant continu sans balai (1) selon la revendication 1, dans lequel les bobines excitantes (31 ; 32) sont chacune formées par enroulement d'un élément conducteur en forme de bande de manière à ce qu'une direction en largeur de l'élément conducteur s'étend le long d'une direction d'axe de rotation de la bobine excitante (31 ; 32).
  4. Moteur à courant continu sans balai (1) selon la revendication 1, dans lequel l'élément à noyau de fer (20, 40) du stator (2) et le rotor (4) sont chacun formés au choix d'un noyau magnétique pulvérulent constitué de poudre magnétique douce à base de fer ou d'un noyau magnétique en ferrite ou d'un noyau magnétique constitué d'un matériau magnétique doux dans lequel une poudre en alliage magnétique est dispersée en résine.
  5. Procédé de commande du moteur à courant continu sans balai (1) selon la revendication 1,
    comprenant l'application d'un courant positif à une des deux bobines excitantes (31 ; 32) si le rotor (4) est activé dans un sens de rotation vers l'avant ; et l'application d'un courant négatif à l'autre bobine excitante (31 ; 32) si le rotor (4) est activé dans un sens de rotation inverse qui est l'inverse du sens de rotation vers l'avant.
  6. Procédé de commande du moteur à courant continu sans balai (1) selon la revendication 6,
    dans lequel le rotor (4) est accéléré ou normalement tourné par application d'un courant à onde rectangulaire après que le rotor (4) a été activé pour rotation.
EP11845675.5A 2010-12-01 2011-11-18 Moteur à courant continu sans balai et procédé de commande associé Not-in-force EP2648320B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2010268396A JP5167330B2 (ja) 2010-12-01 2010-12-01 Ｄｃブラシレスモータおよびその制御方法
PCT/JP2011/006433 WO2012073446A1 (fr) 2010-12-01 2011-11-18 Moteur à courant continu sans balai et procédé de commande associé

Publications (3)

Publication Number Publication Date
EP2648320A1 EP2648320A1 (fr) 2013-10-09
EP2648320A4 EP2648320A4 (fr) 2016-03-23
EP2648320B1 true EP2648320B1 (fr) 2017-01-04

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US (1) US10355625B2 (fr)
EP (1) EP2648320B1 (fr)
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WO (1) WO2012073446A1 (fr)

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Also Published As

Publication number Publication date
US20130234540A1 (en) 2013-09-12
EP2648320A1 (fr) 2013-10-09
JP5167330B2 (ja) 2013-03-21
EP2648320A4 (fr) 2016-03-23
US10355625B2 (en) 2019-07-16
WO2012073446A1 (fr) 2012-06-07
JP2012120342A (ja) 2012-06-21

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